1. don't know, should be real close, frame to can difference to look at
3. The 3/4 female bung in the C can hole is return coolant, the one on the bottom is suction. The pump, the long threaded section goes into the tank. Either threaded in or just a hole and the gasket. May be best to not break a pump installing it. BUT a lid like you show above would be needed to get into the tank to screw on the "nut" and gasket to seal the pump in place.
If 1 off and $100 I think I would draw it up for you. I have been planning to just make something in there but making "something" fit in that location could fall in front of the tires lol.
There is other uses though. Would be great for a devils own tank, out of the way under the hood. Any water to air type system can use a tank in that location. This is going to be something I need to measure for. Don't want the pump hanging down for the whole world to see lol. Don't want to go through the expense and not have enough volume. So I'll measure something up tomarrow
Oh yeah....you have to get into the tank to screw the flange for the pump on..I'm not sure I follow you about the lip. I would imagine a hand-sized hole to allow you to reach in and hold the pump flange. And an associated sealed lid of some kind to block the hole. Rats. I guess something can be figured out for that. Maybe just a plate with a gasket on the side of the tank?
Making a tank like this in sheet aluminum, with bosses, threaded NPT ports, and holes is definitely within my "fast prototyping" zone. The hand-sized hole with sealed cap is a sticking point, but maybe we'll figure out some way around that. I've got filler rod, gas, and tons of sheet metal in the garage, I can make the threaded bosses myself, and I can buy a tap to make the threaded fittings. I may actually be able to scream through this. We need to figure out how to connect the pump to the tank though...Threading it in is quite awkward. What about another piece of some kind? Maybe an adapter that converts the pumps flange fitting into a hose or something that connects to the tank?
I still dont get the tank having three ports...so the pump sucks water in from the tank through its long flanged fitting, and spits it out to a hose which goes elsewhere (intercooler, etc..), then the return from that goes to the fitting in the top of the tank...
Whats the extra NPT fitting on the bottom do? Im dumb..
Yep I can do this for $100 shipped so far. Anyone else want one?